How does Proximity Alert System help in workplace safety?

How does Proximity Alert System help in workplace safety?
Published On: December 12, 2022 Revised On: March 6, 2024

Forklift accidents often occur in crowded or noisy workplaces, and the workers on site are the most vulnerable in workplace accidents. Accidental collisions may happen when a worker is unaware of a nearby vehicle operating. A proximity alert system is a safety device that alerts the material handling equipment (MHE) when approaching a worker in danger. This system typically employs sensors and alerts to provide real-time warnings.

The equipment can be installed into forklifts, reach stackers and gantry cranes. There are other safety systems, such as a monitoring system. This article will share more on the proximity alert system to help improve workplace safety in a warehouse. By deploying these systems, industries can safeguard employees and maintain efficient workflows, making them an integral part of today’s industrial safety protocols.

Understanding Proximity Alert System

A proximity alert system is a vehicle-to-individual and vehicle-to-vehicle proximity warning technology that prevents accidents involving workers and heavy equipment operating near one another. The primary technology proximity alert systems use to protect and detect in any warehouse is frequency magnetic fields.

They can recognise the presence of other devices and provide relevant messages or alerts to workers on the ground. Most alert sensors will provide a binary (on/off) signal when near an object. This signal will immediately convey the readings from the proximity alert sensors or at a specified interval (such as every five seconds).

Forklift alert systems function by constantly monitoring a predefined space. Sensors capture data and relay it to the control unit, which then determines if an alert is warranted based on the proximity of detected objects. Depending on the type of system—be it RFID, ultrasonic, or infrared—the technology employed varies. Still, the goal remains consistent: to notify users of imminent objects or individuals in real-time, ensuring safety and preventing collisions.

Types of Proximity Alert Systems:

Ultrasonic: These systems deploy sound waves at frequencies beyond human hearing to detect objects. The reflection of these waves indicates the presence of an obstacle.

Infrared: Working on the principle of infrared radiation emitted by all objects, these systems detect changes in radiation, signalling the proximity of an object or person

RFIDs (Radio Frequency Identification): Utilizing radio-frequency waves, RFIDs identify and track tags attached to objects, making them ideal for inventory tracking and management.

Radio frequencies are used by forklift trucks with radio frequency identification tags to sound an alarm when a worker enters the area. Only RFID-tagged workers can use this technology. When a person is near a forklift truck while wearing an RFID tag, the RFID tag generates a radio signal that is picked up by the alarm system. The RFID forklift system can be used in two different ways:

Method 1: The RFID forklift reader is mounted in a fixed position (blind spot, intersection, warehouse entrance). RFID tags are placed on elevators to alert staff members that a lift is nearby, and when a lift enters the specified vicinity, an alarm rings.

Method 2: The RFID reader is attached to the elevator, and the workers wear the RFID tags. When workers are within the specified vicinity of the elevator, the alarm and lights go off.

Benefits of Forklift Alert Systems

Integrating proximity alert systems offers immediate safety benefits and plays a pivotal role in shaping a more efficient, cost-effective, and positive workplace. The benefits encompass fewer accidents and collisions, bolstered safety measures, substantial financial savings by averting accidents and reducing downtime, and a notable boost in worker morale and confidence.

  • Immediate Detection: PAS provide real-time data, ensuring swift responses to potential hazards.
  • Precision: Advanced sensors can accurately gauge distances, significantly reducing the chances of equipment or personnel entering unintended contact.
  • Comprehensive Monitoring: Continuous surveillance means no blind spots or unmonitored areas, ensuring all-round safety.
  • Standardization: With PAS, industries can implement standardized safety protocols, leading to consistent safety practices across the board.
  • Cost-Effective: While the initial investment might seem substantial, the long-term savings from avoided accidents, machinery repairs, and operational halts ensure that PAS are cost-effective.
  • Increased Productivity: Minimized downtime due to fewer accidents means operations run smoother and more efficiently.
  • Safety Assurance: When workers know they’re protected, they can focus better on their tasks without constantly fearing potential accidents.
  • Job Satisfaction: A safer environment fosters better job satisfaction, as workers feel valued and protected, leading to improved morale and potentially higher retention rates.

Key Features to Consider

When evaluating a PAS, the focus should be on its adaptability, efficiency, and effectiveness, ensuring it aligns with the specific demands and nuances of the intended environment.

Detection Range and Accuracy:  Depending on the specific environment, the ideal PAS should have adjustable detection ranges to cater to varying operational needs. The accuracy with which the system detects objects or personnel is essential. A system’s reliability is directly linked to its precision in identifying potential threats.

Alert Mechanisms: Visual alerts like flashing LEDs or screen prompts are critical in well-lit or daylight scenarios. A distinct and discernible sound alert in noisy environments ensures the warning isn’t lost amidst the ambient noise. Especially beneficial for operators wearing heavy protective gear or in high-noise zones, vibration alerts can be felt physically, ensuring immediate attention.

System Integration: The chosen PAS should seamlessly integrate with existing machinery, software, and operational protocols. Implementation should not necessitate massive overhauls. The system should be designed to fit into the current infrastructure with minimal disruptions to operations.

Power Consumption: The system’s battery life should last through shifts without frequent recharges or replacements for continuous operations. A well-designed PAS is energy-efficient, balancing power consumption with performance and ensuring operational continuity while conserving energy.


Proximity alert systems are useful to various industries, addressing safety concerns across varied sectors. Their primary function, preventing collisions and accidents, underscores their importance. As industries continue to grow and evolve, such systems ensure safety and efficiency.

Humi Pak is a supplier of proximity alert systems in Malaysia, offering various components tailored to various work environments. Beyond supplying, we provide comprehensive training and maintenance services to ensure optimal system performance. To understand how our systems can benefit your operations, feel free to contact our engineers for a detailed demonstration.

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